AEROSOL SEPARATOR ASSEMBLY; COMPONENTS; AND METHODS
A filter cartridge for use in separating a hydrophobic liquid aerosol phase from a gas stream, as a crankcase ventilation filter for example, is described. The cartridge includes a media pack comprising filtration media surrounding an open interior and a first end piece. Various structure included on the first end piece is described. An example is a D-shaped projection. Also described is an assembly including the filter cartridge, specific features of a housing component of the assembly. Methods of assembly and use are also described.
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This application is being filed on 19 Mar. 2008 as a PCT International Patent application in the name of Donaldson Company, Inc., a U.S. national corporation, applicant for the designation of all countries except the US, and Thomas John Lundgren, Bradley Allen Hemish, Daniel Eric Adamek, and Wade Mosset, all citizens of the U.S., applicants for the designation of the US only, and claims priority to U.S. Provisional Patent Application Ser. No. 60/919,254, filed Mar. 20, 2007.
FIELD OF THE DISCLOSUREThis disclosure relates to systems and methods for separating hydrophobic fluids (such as oils) which are entrained as aerosols, from gas streams (for example air streams). Further, the arrangements also provide for filtration of other contaminants, such as carbon material, from the gas streams. The arrangements are typically used to filter crankcase ventilation gases, from engine systems. Methods for conducting the separations are also provided.
BACKGROUNDCertain gas streams, such as engine blow-by gases (i.e., crankcase ventilation gases, from the crankcases of the diesel engines) carry substantial amounts of entrained oils (liquid) therein, as aerosol. The majority of the oil (liquid) droplets within the aerosol are often within the size of 0.1-5.0 microns.
In addition, such gas streams also carry substantial amounts of fine particulate contaminant, such as carbon contaminants. Such contaminants often have an average particle size within the range of about 0.5-3.0 microns. In some systems, it is desirable to vent such gases to the atmosphere.
In general it is preferred that before the gases are vented to the atmosphere, they be cleaned of a substantial portion of aerosol and/or organic particulate contaminate therein.
In other instances, it is desirable to direct the air or gas stream into equipment. When such is the case, it may be desirable to separate aerosolized liquids and/or particulates from the stream during circulation, in order to provide such benefits as: reduced negative effects in the downstream equipment; improved efficiencies; recapture of otherwise lost oil; and/or, to address environmental concerns.
Improvements in crank cases ventilation filter systems (i.e., blow-by gas filtration systems) constructed for application with a variety of engine or equipment systems, are generally sought.
SUMMARY OF THE DISCLOSUREHerein, assemblies, components, and techniques and features usable for crankcase ventilation systems are described and shown. There is no specific requirement that a system component or applied technique include all of the specific features described herein, to obtain some advantage or benefit according to the present disclosure.
In general, a crankcase ventilation filter assembly is described, including the housing defining a gas flow inlet, gas flow outlet and a liquid drain arrangement; and, a serviceable filter cartridge removably positioned within an interior of the housing. The term “serviceable” in this context, when used herein to reference a filter cartridge, is meant to refer to a filter cartridge that can be removed from the housing, to be serviced or replaced in a housing. Herein the term “serviceable” in this context is meant to be synonymous with “removable” or “removable and replaceable”.
The housing generally includes: a housing base; and, an access cover which was removably mounted on the housing base to provide service access to an interior of the assembly. For an example described, the cover is threadably mounted on the housing base; and, the housing base includes the gas flow inlet, a gas flow outlet and liquid drain arrangement therein.
Herein a cartridge-to-housing base (or housing base-to-cartridge) rotational alignment indexing arrangement is described, assuring that the cartridge can only be positioned in the base in the single, selected, rotational orientation. Also, a cartridge-to-access cover portion (or access cover portion-to-cartridge) rotational alignment indexing arrangement is described, ensuring that a portion of the housing access cover can only be oriented a single, selected, rotational orientation relative to the cartridge, in the assembly.
Also described is a unique cartridge arrangement, including, among other things, an end piece with a flow aperture arrangement therethrough, and a non-circular projection addition around the flow aperture arrangement. An example of a circular projection having a “D” shape is described. A specific example is depicted, in which a straight side portion of the “D” projection, opposite a curved section, includes liquid flow aperture or gap arrangement therethrough.
Other advantageous features in the housing, the access cover and the filter cartridge are described herein below.
The reference numeral 1,
In general, the housing 2 includes gas flow inlet 10, liquid drain outlet 11 and gas flow outlet 12. For the example assembly 1 depicted in
In use, blow-by gases (crankcase ventilation gases) are directed into the assembly 1 through inlet 10. Within the assembly 1, at least a portion of liquid particles (droplets) carried within the crankcase ventilation gases are coalesced, and drain outwardly from the assembly through drain outlet 11, typically at least under gravity influence. The gases are filtered, and the outlet gases leave the assembly 1 through gas outlet 12.
The access or service cover or cover assembly 4 is removable from base 3. After a period of use, an internally received cartridge 5 will typically need to be serviced, for example by refurbishment or replacement. When such is the case, the access cover 4 is removed; the cartridge 5 is removed from the assembly 1; and, a new or refurbished cartridge 5 is installed. Herein the cartridge 5 which is removable and replaceable within the housing 2, is generally referenced as a “serviceable” cartridge.
In
In
Referring again to
Attention is now directed to
Referring still to
In general, the regulator valve assembly 20 comprises a diaphragm 21 supported by a biasing arrangement 22. The diaphragm 21 is flexible, and is mounted to regulate flow of gases through flow aperture arrangement 35 into cartridge open interior 30. The biasing arrangement 22 typically comprises a coiled spring 23.
In
Referring again to
Liquid drained from the media 31 can flow out from outer surface 310 of media 31. Liquid flow can also occur directly downwardly through a bottom end 39 of media 31, when the cartridge 5 includes a bottom liquid drain arrangement as depicted, and as discussed below. By “directly downwardly” in this context, it is meant that the liquid drainage referenced can be out of the media 31 through end 39, without necessarily needing to exit through surface 31d.
It is noted that open interior 30 of media 31 (and cartridge 5) includes an inner support structure 40, in the form of a tubular grid with an openings therein.
Cartridge 5 can be provided with a outer, porous, liner, not depicted, around outer surface 310 media 31, if desired.
Referring to
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For the system shown, the inlet 10, the regular valve assembly 20, and interior 30 of cartridge 5, are located on the upstream side of the seal 45 and media 31. The clean gas annulus 33, drain 11, and the outlet 12 are on the downstream side of the housing seal arrangement 45.
Referring again to
Aerosolized liquid contained within the inlet gas stream at inlet 10, can begin to coalesce along housing surfaces upstream of, and in some instances below, diaphragm 21. It is noted that a lower portion 10L of the inlet 10, at which such coalescing may occur, is located lower than a top 48u of flange 48f, and also lower than flow aperture arrangement 35 of cartridge 5. For coalesced liquid within inlet 10 and around region 48f to reach interior 30, the coalesced liquid must be directed to a location above top end 48u of region 48f.
Referring to
In general, the trough or gutter arrangement 55 is in part defined between a portion of upper flange 48f (
Attention is now directed to
For the example shown, upper portion 3u in access opening 57 defines a generally circular shape. It is noted that the circular shape of flange 48
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From the discussions with respect to
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As an example, during manufacture of assembly 1, mounting arrangement 15 can be appropriately rotationally positioned in housing base 3, for a particular installation. The part can then be shipped with mounting arrangement 15 appropriately positioned, and thus will be received by an installer assembly as facilitated.
Referring to
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End piece 70 includes central aperture arrangement 35, extending therethrough, in flow communication with open interior 30,
End piece 70 includes a first outer surface 70s on a side of end piece 70 opposite the media 31.
The upper end piece 70 includes a plurality of additional features including: outer circumferential rim 71 with a trough 71a supporting perimeter housing seal arrangement 45 (in the example shown comprising o-ring 46). As described in connection with
End piece 70 of cartridge 5,
The projection 38 is positioned around aperture arrangement 35,
It is noted that flange 38, for the example shown, defines a non-circular perimeter definition. The non-circular perimeter definition is discussed further below, in connection with other figures. In general, the non-circular perimeter facilitates rotational alignment with other features in the assembly 1.
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When cartridge 5 is fully inserted in base 3, one of the cartridge locator projections 80, i.e., projection 80a will extend into the receiver 90, between projection 85 and shoulder 88; and the other projection 80b will extend into the receiver 91 between projection 86 and shoulder 89. Receivers or gaps 90, 91, are spaced on center, in at least one radial direction, a distance corresponding to an angle of less than 180°. The receivers or gaps 90, 91 will typically be sized to just fit, with a little clearance, the projections 80a, 80b. The non-symmetrical (rotational) positioning of the ears 80a, 80b, around rim 57, will ensure that there is only one rotational position allowing cartridge 5 to be fully nested inside of base 3. That rotational orientation is shown in
In general terms, referring to
In
Referring still to
The handle arrangement 95 is often referred to herein as a “perimeter” or “peripheral” arrangement, or by similar terms, since the handle arrangement 95 is secured to cartridge 5 at the perimeter region of end caps 70.
For the example shown, the handle arrangement 95 is “non-collapsible.” By this, it is meant that the handle 95 remains upright, i.e., does not fold over otherwise collapse during installation of the cartridge 5 in the housing base 3. The term “non-collapsible” in its context, is not meant to indicate that the handle 95 cannot be collapsed by being broken if sufficient pressure is applied. Rather it is meant that in normal use of the handle arrangement 95 maintains a single orientation, and is not collapsed or folded during its normal use or handling.
Handle aperture 96 is depicted located in radial alignment with aperture 10i. This facilitates flow of air from inlet 10 across end piece 70 to aperture 35 for flow into cartridge interior 30. The handle aperture 96 also provides a convenient arrangement with handle bridge 95a, for grasping during installation and servicing. Thus, bridge 95a and handle aperture 96 are typically sized to accommodate a portion of service operator's hand projecting through aperture 96, to facilitate grasping of cartridge 5.
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In general terms, cartridge 17 includes a bottom end piece 100, in use, which includes bottom drain arrangement therein. The bottom drain arrangement comprises apertures, notches, or other features allowing for drainage of liquid for the media pack 31 direction downwardly, from the media pack 31, without the liquid needing to flow out of surface 310 of media 31 (i.e., from outer surface 5x of the cartridge 5). It is expected in a typical applications there will be liquid drainage both through outer edge 5x and also directly downwardly through the liquid drain arrangement, in this instance represented by drain openings 101o.
The cartridge 17, then, can be characterized as having an aperture arrangement in “direct drain overlap” with a bottom end of the media 31. By “direct drain overlap” in this context, it is meant that the drain aperture opening or drain apertures 101o, are aligned with a bottom end 39 of the media 31, so the liquid can drain directly from the media 31 through the drain openings 101o, without needing to necessarily pass through an outer surface 310 of the media 31. In typical operation, the liquid will flow both directly downwardly through the liquid drain arrangement, and outwardly from outer surface 31o of the media pack 31, to provide for a good liquid drainage flow from the media 31.
A good liquid drainage flow from the media 31 facilitates operation of the assembly 1, since drainage of liquid is important to overall operation of the cartridge 5. Incorporation of a bottom drain arrangement allowing for liquid flow both from the bottom of the media pack 31 and from the outer surface 31o, facilitates good drainage.
Bottom drain arrangements in general, for crankcase ventilation filters, are described in U.S. provisional application 60/731,287 filed Oct. 28, 2005 and PCT application US 06/41738 filed Oct. 27, 2006, each of which is incorporated herein by reference.
Referring again to
Attention is now directed to
For the example shown, gap 75 is through a portion of straight side section 126.
The particular flange 38 shown, has a D-shape; i.e., a D-shaped inner definition and outer perimeter. In the particular example shown, straight side 126 is directed toward handle 95 and handle aperture 96, and includes gap 75 therethrough.
In general terms, the perimeter shape of projection 38 can be provided in a variety forms, preferably none of which is radially symmetric. By this, again, it is meant that to overlap itself and define the same perimeter, the projection 38 would need to be rotated a full 360° around central axis Z (
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Ribs 130, of double rib arrangement 140, and ribs 130 will strengthen central support region 140 and will facilitate rotational indexing of a portion of access cover assembly 4 with cartridge 5 and housing base 3.
C. The Access Cover Assembly 4 of FIGS. 11-16.Referring to
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In general terms, the access cover assembly 4 includes a snap-fit projection arrangement, for securing cap member 150b to basket member 151. The snap-fit projection arrangement, in the example shown, comprises a plurality of snap-fit projection 150c on the cap member 150b.
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In general, referring to
In addition, in
Referring now to
In more general terms, the cover assembly 4 includes a cap member-to-basket member (or basket member-to-cap member) rotational alignment indexing arrangement including a projection/receiver arrangement. The projection/receiver arrangement includes a first projection member on one of the cap 150b and basket 151; and a second receiver member on a second one of the cap 150b and basket 151. For the example described, the projection member is on the cap 150b, and comprises snap-fit hooks 150c and first and second projection members 164, 165; and, the receiver member is positioned on the basket 151 comprises a space under rim 151r, flanges 151f and first and second receivers 162, 163. The projection/receiver arrangement operates to provide a cap member-to-basket member rotation alignment indexing arrangement, which ensures that the cap member 150b can only be positioned in engagement with the basket member 151 in a single, selected, rotational orientation, in which it will remain.
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The outer ring section 170 (
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In more general terms, projection 190 preferably defines a perimeter shape which must be rotated 360° (one complete time) around central axis Z,
For the example shown,
Clearance along a bottom end 138b (
Typically, a gap or clearance of at least 0.3 mm in this region is sufficient. Typically the gap or clearance will typically be about 1 mm-5 mm, for example 2-5 mm. In
Alternately stated, typically projection 190 is sufficiently shorter than projection 30a, such that projection 190 projects into projection 30a a short distance, leaving a gap of at least 0.3 mm, typically at least 1 mm and often on the order of 2-5 mm, for example 4 mm, between an end projection 190 and a bottom end of projection 30a, adjacent aperture arrangement 35.
Referring again to
In addition to gap 200,
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From the above, it will be understood the assembly 1 is configured for a single, defined, rotational alignment of base 3, cartridge 5, basket member 151 and cap 150b. When properly assembled, cap 150b will be oriented with designator 10x, i.e., “IN” aligned with inlet 10,
In general, the cover member 4 will not be able to press downwardly into a secure engagement, unless receiver 200 in center projection member 191, is aligned with gap 75 and double rib arrangement 140.
Attention is directed to
In
In
In the examples depicted in
Of course alternative dimensions can be used with the current principles.
A variety of materials can be used for the structural materials, and typically are a matter of a choice.
Typically for the housing base 3, a plastic will be chosen, for example a glass-filled (33%) nylon 66 or similar material. For the cover assembly 4, the cap member 150a and basket member 151, would typically comprise a molded plastic, for example nylon 66, glass-filled (33%). The rim member 150b will typically comprise an Acetal.
Within the cartridge 5, the support member 110 will typically comprise a molded plastic, for example a glass-filled (33%) nylon 66 or similar material can be used. The mounting arrangement 15 would typically comprise glass-filled (33%) nylon 66.
The media or media 31 is described in Section RI below.
II. Example System, FIG. 21Attention is directed to
Of course the off gases 252 can be directed elsewhere, for example into air cleaner 260, if desired.
In general, the system 250 depicted is “closed” in that filtered off gases from the filter arrangement 1 are not vented directly to the atmosphere, but rather are cycled back into the engine intake indicated generally at 270.
Although not shown, a typical system 250 would include pressure relief valve assembly ensuring that crankcase ventilation flow from the engine 251 is vented to the atmosphere, if the filter arrangement 1 or equipment downstream from filter arrangement, is sufficiently occluded to build up pressure to an otherwise (if not vented) undesirable level.
III. Useable Media A. General CharacteristicsThe appropriate media, for the media pack, is selected for the conditions of use. Generally the media is selected to have appropriate properties with respect to: coalescing and drainage of liquid; and, filtering of gases passing therethrough with respect to particulates. Layers of media can be utilized for the media of the media pack. Example usable media described in U.S. Provisional Application Ser. No. 60/731,287, filed Oct. 28, 2005, PCT Application PCT/US2006/041738, filed Oct. 27, 2006, U.S. Provisional Application 60/656,806, filed Feb. 22, 2006; and, PCT Publication WO06/91594, published Aug. 31, 2006, and PCT Publication WO 2006/084282, published Oct. 19, 2006, each of which is incorporated herein by reference.
Typically the media will comprise a continuous, non-woven, fibrous media.
An example useable media as described in U.S. provisional application 60/656,806 filed Feb. 22, 2005, incorporated herein by reference. Another example media is described in PCT Publication WO 05/083,240, published Sep. 9, 2005, and incorporated herein by reference. A third example media is described in U.S. provisional application 60/650,051 filed Feb. 4, 2005, incorporated herein by reference. The following description is of example media from U.S. provisional application 60/650,051, filed Feb. 4, 2005.
The media is typically a wet laid media is formed in a sheet form using wet laid processing, and is then positioned on/in the filter cartridge. Typically the wet laid media sheet is at least used as a media stage stacked in multiple layers.
As indicated, multiple layers, forming a gradient can be provided in a media stage, by first applying one or more layers of wet laid media of first type and then applying one or more layers of a media (typically a wet laid media) of a different, second, type. Typically when a gradient is provided, the gradient involves use of two or more media types which are selected for at least differences in efficiency.
Herein, it is important to distinguish between the definition of the media sheet used to form the media stage, and the definitions of the overall media stage itself. Herein the term “wet laid sheet,” “media sheet” or variants thereof, is used to refer to the sheet material that is used to form the media extension of a filter, as opposed to the overall definition of the total media extension in the filter. This will be apparent from certain of the following descriptions.
Media extensions of the type of primary concern herein, are at least used for coalescing/drainage, although they typically also have particulate removal function and thus comprise a portion of an overall media stage that provides for both coalescing/drainage and desired removal efficiency of solid particulate removal.
Although alternatives are possible, an example media composition used to form a media extension in a CCV (crankcase ventilation) filter for coalescing/drainage is typically as follows:
-
- 1. Although alternatives are possible for different applications, it is typically provided in a form having a calculated pore size (X-Y direction) of at least 10 micron, usually at least 12 micron. The pore size is typically no greater than 60 micron, for example within the range of 12-50 micron, typically 15-45 micron.
- 2. It is typically formulated to have a DOPE % efficiency (at 10.5 fpm for 0.3 micron particles), within the range of 3-18%, typically 5-15%.
- 3. It typically comprises at least 30% by weight, typically at least 40% by weight, often at least 45% by weight and usually within the range of 45-70% by weight, based on total weight of filter material within the sheet, bi-component (binder) fiber material in accord with the general description provided herein.
- 4. It typically comprises 30 to 70% (typically 30-55%), by weight, based on total weight of fiber material within the sheet, of secondary fiber material having average largest cross-sectional dimensions (average diameter if round) of at least 1 micron, for example within the range of 1 to 20 micron. In some instances it will be 8-15 micron. The average lengths are typically 1 to 20 mm, often 1-10 mm. This secondary fiber material can be a mix of fibers. Typically polyester and/or glass fibers are used, although alternatives are possible.
- 5. Typically and preferably the fiber sheet (and resulting media extension) includes no added binder other than the binder material contained within the bi-component fibers. If an added resin or binder is present, preferably it is present at no more than about 7% by weight of the total fiber weight, and more preferably no more than 3% by weight of the total fiber weight.
Media in accord with the general definitions provided herein, including a mix of bi-component (binder) fiber and other fiber, can be used as any (and in some instances all) layer(s) of a media stage in a crankcase ventilation filter as generally described above. When used in this manner, it will typically be placed in multiple layers, although alternatives are possible. The overall efficiency can be calculated based upon the number of layers and the efficiency of each layer. For example the efficiency at 10.5 feet per minute (3.2 m/min) for 0.3 micron DOPE particles for media stage comprising two layers of wet laid media each having an efficiency of 12% would be 22.6%, i.e., 12%+0.12×88.
Typically enough media sheets would be used in the final media stage to provide the media stage with overall efficiency of at least 85%, typically 90% or greater. In some instances it would be preferred to have the efficiency at 95% or more. In the context the term “final media stage” refers to a stage resulting from wraps or coils of the sheet(s) of the media.
B. The Preferred Calculated Pore Size.The media extension performs two important functions:
-
- 1. It provides for some coalescing and drainage of oil particles carried in the crankcase ventilation gases being filtered; and
- 2. It provides for selected filtration of other particulates in the gas stream.
In general, if the pore size is too low:
-
- a. Drainage of coalesced oil particles by gravity, downwardly through (and from) the media, can be difficult or slowed, which leads to an increase of re-entrainment of the oil into the gas stream; and
- b. Unacceptable levels of restriction are provided to the crankcase gas flow through the media.
In general, if the porosity is too high:
-
- a. Oil particles are less likely to collect and coalesce; and
- b. A large number of layers, and thus media thickness, will be necessary to achieve an acceptable overall level of efficiency for the media pack.
It has been found that for crankcase ventilation filters, a calculated pore size for media used to form media extension within the range of 12 to 50 micron is generally useful. Typically the pore size is within the range of 15 to 45 micron.
The term X-Y pore size and variants thereof when used herein, is meant to refer to the theoretical distance between fibers in a filtration media. X-Y refers to the surface direction versus the Z direction which is the media thickness. The calculation assumes that all the fibers in the media are lined parallel to the surface of the media, equally spaced, and ordered as a square when viewed in cross-section perpendicular to the length of the fibers. The X-Y pore size is a distance between the fiber surfaces on the opposite corners of the square. If the media is composed of fibers of various diameters, the d2 mean of the fiber is used as the diameter. The d2 mean is the square root of the average of the diameters squared.
It has been found, in some instances, that it is useful to have calculated pore sizes on the higher end of the preferred range, typically 30 to 50 micron, when the media stage at issue has a total vertical height, in the crankcase ventilation filter of less than 7 inches (178 mm); and, pore sizes on the smaller end, about 15 to 30 micron, are sometimes useful when the filter cartridge has a height on the larger end, typically 7-12 inches (178-305 mm). A reason for this is that taller filter stages provide for a higher liquid head, during coalescing, which can force coalesced liquid flow, under gravity, downwardly through smaller pores, during drainage. The smaller pores, of course, allow for higher efficiency and fewer layers.
Of course in a typical operation in which the same media stage is being constructed for use in a variety of filter sizes, typically for at least a portion of the wet laid media used for the coalescing/drainage in initial separation, an average pore size of about 30-50 microns will be useful.
C. SoliditySolidity is the volume fraction of media occupied by the fibers. It is the ratio of the fibers volume per unit mass divided by the media's volume per unit mass.
Typical materials preferred for use in media extension according to the present disclosure, have a percent solidity at 0.125 psi (8.6 milliards) of fewer than 10%, and typically fewer than 8%, for example 6-7%.
D. Preferred DOPE Efficiency at 10.5 ft/Minute for 0.3 Micron Particles.
The preferred efficiency stated, is desirable for layers or sheets of media to be used to generate crankcase ventilation filters. This requirement indicates that a number of layers of the wet laid media will typically be required, in order to generate an overall desirable efficiency for the media stage of typically at least 85% or often 90% or greater, in some instances 95% or greater.
The reason a relatively low efficiency is provided in any given layer, is that it facilitates coalescing and drainage and overall function.
In general, DOPE efficiency is a fractional efficiency of a 0.3 micron DOPE particle (dactyl phthalate) challenging the media at 10 fpm. A TSAR model 3160 Bench (TSAR Incorporated, St. Paul, Minn.) can be used to evaluate this property. Model dispersed particles of DOPE are sized and neutralized prior to challenging the media.
E. The Media Composition. 1. The Bi-Component Fiber Constituent.As indicated above, it is preferred that the fiber composition of the media include 30 to 70%, by weight, of bi-component (binder) fiber material. A major advantage of using bi-component fibers in the media, is effective utilization of fiber size while maintaining a relatively low solidity. With the bi-component fibers, this can be achieved while still accomplishing a sufficiently high strength media for handling installation in crankcase ventilation filters. Also, the bi-component fibers are binder fibers.
The bi-component fibers generally comprise two polymeric components formed together, as the fiber. Various combinations of polymers for the bi-component fiber may be useful, but it is important that the first polymer component melt at a temperature lower than the melting temperature of the second polymer component and typically below 205° C. Further, the bi-component fibers are integrally mixed and evenly dispersed with the other fibers, in forming the wet laid media. Melting of the first polymer component of the bi-component fiber is necessary to allow the bi-component fibers to form a tacky skeletal structure, which upon cooling, captures and binds many of the other fibers, as well as other bi-component fibers.
Although alternatives are possible, typically the bi-component fibers will be formed in a sheath core form, with a sheath comprising the lower melting point polymer and the core forming the higher melting point.
In the sheath-core structure, the low melting point (e.g., about 80 to 205° C.) thermoplastic is typically extruded around a fiber of the higher melting point material (e.g., about 120 to 260° C.). In use, the bi-component fibers typically have a average largest cross-sectional dimension (average fiber diameter if round) of about 5 to 50 micrometer often about 10 to 20 micrometer and typically in a fiber form generally have an average length of at least 1 mm, and not greater than 30 mm, usually no more than 20 mm, typically 1-10 mm. By “largest” in this context, reference is meant to the thickest cross-section dimension of the fibers.
Such fibers can be made from a variety of thermoplastic materials including polyolefin's (such as polyethylene's, polypropylenes), polyesters (such as polyethylene terephthalate, polybutylene terephthalate, PCT), nylons including nylon 6, nylon 6, 6, nylon 6, 12, etc. Any thermoplastic that can have an appropriate melting point can be used in the low melting component of the bi-component fiber while higher melting polymers can be used in the higher melting “core” portion of the fiber. The cross-sectional structure of such fibers can be a “side-by-side” or “sheath-core” structure or other structures that provide the same thermal bonding function. One could also use lobed fibers where the tips have lower melting point polymer. The value of the bi-component fiber is that the relatively low molecular weight resin can melt under sheet, media, or filter forming conditions to act to bind the bi-component fiber, and other fibers present in the sheet, media, or filter making material into a mechanically stable sheet, media, or filter.
Typically, the polymers of the bi-component (core/shell or sheath and side-by-side) fibers are made up of different thermoplastic materials, such as for example, polyolefin/polyester (sheath/core) bi-component fibers whereby the polyolefin, e.g. polyethylene sheath, melts at a temperature lower than the core, e.g. polyester. Typical thermoplastic polymers include polyolefins, e.g. polyethylene, polypropylene, polybutylene, and copolymers thereof, polytetrafluoroethylene, polyesters, e.g. polyethylene terephthalate, polyvinyl acetate, polyvinyl chloride acetate, polyvinyl butyral, acrylic resins, e.g. polyacrylate, and polymethylacrylate, polymethylmethacrylate, polyamides, namely nylon, polyvinyl chloride, polyvinylidene chloride, polystyrene, polyvinyl alcohol, polyurethanes, cellulosic resins, namely cellulosic nitrate, cellulosic acetate, cellulosic acetate butyrate, ethyl cellulose, etc., copolymers of any of the above materials, e.g. ethylene-vinyl acetate copolymers, ethylene-acrylic acid copolymers, styrene-butadiene block copolymers, Kraton rubbers and the like. Particularly preferred in the present invention is a bi-component fiber known as 271P available from DuPont. Others fibers include FIT 201, Kuraray N720 and the Nichimen 4080 and similar materials. All of these demonstrate the characteristics of cross-linking the sheath polymer upon completion of first melt. This is important for liquid applications where the application temperature is typically above the sheath melt temperature. If the sheath does not fully crystallize then the sheath polymer will remelt in application and coat or damage downstream equipment and components.
An example of a useable bi-component (binder) fiber for forming wet laid media sheets for use in CCV media is Dupont polyester bi-component 271P, typically cut to a length of about 6 mm.
2. The Secondary Fiber Materials.The bi-component fibers provide a matrix for the crankcase ventilation filter media. The additional fibers or secondary fibers, sufficiently fill the matrix to provide the desirable properties for coalescing and efficiency.
The secondary fibers can be polymeric fibers, glass fibers, metal fibers, ceramic fibers or a mixture of any of these. Typically glass fibers, polymeric fibers or a mixture are used.
Glass fibers useable in filter media of the present invention include glass types known by the designations: A, C, D, E, Zero Boron E, ECR, AR, R, S, S-2, N, and the like, and generally, any glass that can be made into fibers either by drawing processes used for making reinforcement fibers or spinning processes used for making thermal insulation fibers.
Non-woven media of the invention can contain secondary fibers made from a number of both hydrophilic, hydrophobic, oleophilic, and oleophobic fibers. These fibers cooperate with the glass fiber and the bi-component fiber to form a mechanically stable, but strong, permeable filtration media that can withstand the mechanical stress of the passage of fluid materials and can maintain the loading of particulate during use. Secondary fibers are typically monocomponent fibers with average largest cross-sectional dimension (diameters if round) that can range from about 0.1 on up, typically 1 micron or greater, often 8-15 microns and can be made from a variety of materials including naturally occurring cotton, linen, wool, various cellulosic and proteinaceous natural fibers, synthetic fibers including rayon, acrylic, aramide, nylon, polyolefin, polyester fibers. One type of secondary fiber is a binder fiber that cooperates with other components to bind the materials into a sheet. Another type of secondary fiber is a structural fiber that cooperates with other components to increase the tensile and burst strength the materials in dry and wet conditions. Additionally, the binder fiber can include fibers made from such polymers as polyvinyl chloride, polyvinyl alcohol. Secondary fibers can also include inorganic fibers such as carbon/graphite fiber, metal fiber, ceramic fiber and combinations thereof.
The secondary thermoplastic fibers include, but are not limited to, polyester fibers, polyamide fibers, polypropylene fibers, copolyetherester fibers, polyethylene terephthalate fibers, polybutylene terephthalate fibers, polyetherketoneketone (PEKK) fibers, polyetheretherketone (PEEK) fibers, liquid crystalline polymer (LCP) fibers, and mixtures thereof. Polyamide fibers include, but are not limited to, nylon 6, 66, 11, 12, 612, and high temperature “nylons” (such as nylon 46) including cellulosic fibers, polyvinyl acetate, polyvinyl alcohol fibers (including various hydrolysis of polyvinyl alcohol such as 88% hydrolyzed, 95% hydrolyzed, 98% hydrolyzed and 99.5% hydrolyzed polymers), cotton, viscose rayon, thermoplastic such as polyester, polypropylene, polyethylene, etc., polyvinyl acetate, polylactic acid, and other common fiber types.
Mixtures of the fibers can be used, to obtain certain desired efficiencies and other parameters.
The sheet media of the invention are typically made using papermaking processes. Such wet laid processes are particularly useful and many of the fiber components are designed for aqueous dispersion processing. However, the media of the invention can be made by air laid processes that use similar components adapted for air laid processing. The machines used in wet laid sheet making include hand laid sheet equipment, Fourdrinier papermaking machines, cylindrical papermaking machines, inclined papermaking machines, combination papermaking machines and other machines that can take a properly mixed paper, form a layer or layers of the furnish components, remove the fluid aqueous components to form a wet sheet. A fiber slurry containing the materials are typically mixed to form a relatively uniform fiber slurry. The fiber slurry is then subjected to a wet laid papermaking process. Once the slurry is formed into a wet laid sheet, the wet laid sheet can then be dried, cured or otherwise processed to form a dry permeable, but real sheet, media, or filter. For a commercial scale process, the bi-component mats of the invention are generally processed through the use of papermaking-type machines such as commercially available Fourdrinier, wire cylinder, Stevens Former, Roto Former, Inver Former, Venti Former, and inclined Delta Former machines. Preferably, an inclined Delta Former machine is utilized. A bi-component mat of the invention can be prepared by forming pulp and glass fiber slurries and combining the slurries in mixing tanks, for example. The amount of water used in the process may vary depending upon the size of the equipment used. The furnish may be passed into a conventional head box where it is dewatered and deposited onto a moving wire screen where it is dewatered by suction or vacuum to form a non-woven bi-component web.
The binder in the bi-component fibers is activated by passing the matt through a heating step. The resulting material can then be collected in a large roll if desired.
3. Surface Treatments of the Fibers.Modification of the surface characters of the fibers, increase in the contact angle, can enhance drainage capability of filtration media and thus the formed elements of the filter (with respect to pressure drop and mass efficiency). A method of modifying the surface of the fibers is to apply a surface treatment such as a flourochemical or silicone containing material, typically up to 5% by weight of the media.
The surface treatment agent can be applied during manufacture of the fibers, during manufacture of the media or after manufacture of the media post-treatment, or after provision of the media pack. Numerous treatment materials are available such as flourochemicals or silicone containing chemicals that increase contact angle. An example is the DuPont Zonyl™ flourochemicals, such as #7040 or #8195.
IV. General Comments and ObservationsHerein, a variety of techniques, features and components, useable for crankcase ventilation filtration, are described. There is no specific requirement that an apparatus or technique involved use all of the features and techniques specifics characterized, in order to obtain some benefit of the teachings of the present disclosure.
In one aspect, the present disclosure relates to a provision of a filter cartridge for use in separating hydrophobic aerosol phase from the gas stream, and to filter the gas stream. The filter cartridge generally comprises a media pack and a first end piece adjacent the media pack. The media pack includes filtration media surrounding an open interior and including first and second opposite ends. The first end piece is positioned adjacent the first end of the media pack, and has a first, outer, surface on an opposite side of the first end piece from the media pack. The first end piece includes a perimeter housing seal arrangement thereon, for example an o-ring seal. The first end piece includes a central flow aperture arrangement projecting therethrough, into flow communication with the open interior of the media pack. The first end piece also includes a non-circular projection surrounding the central flow aperture arrangement. The non-circular projection is positioned to project from an opposite side of the first end piece from the media pack. The direction of extension is thus generally in a direction axially opposite the media pack. By “axially opposite” in this context, it is meant in a direction generally in the same direction as a central axis of the media pack extending through the open interior, but in a direction away from the media pack. When it is said that the piece extends in a direction “axially opposite the media pack,” it is not meant that the non-circular projection extends necessarily precisely parallel to the central axis of the media pack.
The non-circular projection is spaced inward from an outer perimeter or perimeter rim of the end piece.
In general, the “non-circular projection” generally has a radially asymmetric shape. By the term “radially asymmetric” and variants thereof, in this context, it is meant if rotated around a central axis, the projection shape is such that it will only align with itself after a complete (i.e., 360°) rotation.
Typically the non-circular projection includes an outer perimeter with first straight side portion and an opposite curved side portion. An example is shown in which the non-circular projection comprises a D-shaped outer perimeter.
Typically, the non-circular projection is non-continuous and includes a liquid drain gap arrangement extending through a sidewall thereof. In an example shown, the drain gap arrangement comprises a gap in the first straight side portion of the non-circular projection, opposite the curved side portion.
In accord with principles described herein, the cartridge may include a handle member positioned on the first end piece and projecting in a direction away from the media pack. The handle member is typically non-collapsible, i.e., does not fold or collapse in use, but rather remains projecting from the first end piece. The direction of projection is generally axially away from the media pack, although extension precisely parallel to a central axis is not intended to be meant by this.
The handle member includes a bridge section forming a handle opening thereunder, allowing a portion of a person's hand to pass through the handle member under the bridge section, between the bridge section and adjacent portion the first end piece (i.e., between the bridge section and media pack). The handle member is typically a perimeter handle member positioned adjacent an outer perimeter of the first end piece.
Typically, the handle member is oriented with a handle opening aligned with, and directed toward, a first straight side portion of the non-circular projection, when a D-shaped or other non-circular projection with a straight side portion is present.
In a typical arrangement, the first end piece includes a peripheral rim projection extending in a direction away from the media pack. The peripheral rim projection surrounds a recessed surface portion of the first end piece; the recessed surface portion extending between the peripheral rim projection and the non-circular portion surrounding the central flow aperture arrangement.
The peripheral rim projection typically includes an outer surface with an o-ring retaining groove therein; and, the cartridge includes an o-ring mounted in the retaining groove, as a housing seal arrangement.
Typically, the first end piece includes a portion of a cartridge-to-housing base (or housing base-to-cartridge) rotational alignment indexing arrangement thereon. This portion includes a first radial projection spaced from a locator shoulder to define a first locator gap or receiver space therebetween.
A typical cartridge-to-housing base (or housing base-to-cartridge) rotational alignment indexing arrangement includes a pair of locator gaps or receiver spaces (receivers), each defined by radial projection and a locator shoulder. The locator gaps or receivers are typically spaced, radially, on center, by a radial amount of less than 180°. Also typically radial projections used to define the locator gaps (receiver(s)) include a pair of projections spaced by a smallest radial amount on center, of less than 180°.
The cartridge typically includes a second end piece positioned spaced from the first end piece with the media pack positioned therebetween. The second end piece and the first end piece are typically positioned on opposite ends of a central, tubular, media support that extends through the open interior of the media pack. The first end piece, the second end piece and the tubular support may comprise portions of an integral molded support piece, such as a plastic piece.
The second end piece can include the closed central aperture overlapping and closing the end of the open interior of the media pack; and, an outer perimeter section comprising a plurality of spaced projections and a plurality of drain regions between the spaced projections. The drain regions would be positioned at least in part in direct drain overlap with an end in the media pack, at a location adjacent the second end piece. This provides for a bottom drain arrangement for the cartridge, in use.
Also according to the present disclosure, a crankcase ventilation filter assembly is provided. This assembly may include a cartridge, as previously characterized.
In general terms, the crankcase ventilation filter assembly includes a housing defining an interior including a housing base and a removable access cover. The housing generally includes a gas flow inlet arrangement, a gas flow outlet arrangement and a drain arrangement. Each of the inlet arrangement, outlet arrangement and drain arrangement can be positioned in the housing base.
The housing further includes a first rotational indexing alignment arrangement. The first rotational alignment indexing arrangement generally comprises a cartridge-to-housing base (or housing base-to-cartridge) rotational alignment indexing arrangement.
When the cartridge-to-housing base rotational alignment indexing arrangement is present, the housing base includes a first member of the rotational indexing alignment arrangement and the serviceable filter cartridge includes a second member of the rotational indexing alignment arrangement. The two members are oriented to engage one another, only when the cartridge in a single, selected, rotational orientation within and relative to the housing base, allowing the cartridge to be installed in only the selected rotation orientation.
As an example, the cartridge can include a media pack and a first end piece adjacent a first end of the media pack. The first end piece can include a perimeter housing seal arrangement sealed to a portion of the housing base, and a member of a cartridge-to-housing base rotational indexing arrangement for engagement with a second member of the cartridge-to-housing base rotational indexing arrangement on the housing base. Again the arrangement should be such as to require the cartridge to be at a single selected rotational orientation relative to the housing base, when installed.
An example cartridge-to-housing base rotational alignment indexing arrangement is described which includes at least a first projecting tab, and typically a pair of tabs, on the housing base; and, at least a receiver space, and typically two receiver spacers, formed on the first end piece of the filter cartridge, each receiver space being positioned to receive, therein, a single projection on the housing base only when the cartridge is in the selected, single, rotational orientation relative to the housing base.
Typically, the configuration of the projecting tab(s) and the receiver space(s) is such that the cartridge cannot be fully nested within the housing base, unless the single, selected, rotational orientation between the two is obtained.
In general terms, a crankcase ventilation filter assembly as described includes an access cover which includes a first member of a second (access cover portion-to-cartridge or cartridge-to-access cover portion) rotational alignment indexing alignment arrangement. When the cartridge-to-access cover portion rotational alignment indexing alignment arrangement is present, the access cover includes a first member and the cartridge includes a second member, the first and second members only being engageable when a single, selected, rotational orientation is obtained for the access cover portion to the filter cartridge. In an example, the first member comprises a non-circular projection on the access cover, and the second member comprises a non-circular projection on the first end piece of the cartridge; the two non-circular projections only being engageable in a single, rotational, orientation. In an example described, each non-circular projection has a “D” shaped perimeter definition, comprising a first straight side and a second, opposite, curved side. In a typical arrangement, a non-circular projection on the cartridge is sized to receive, projecting therein, a non-circular projection on the access cover.
Typically the non-circular projection on a cartridge includes a liquid flow gap arrangement therethrough, and is oriented surrounding an open aperture in the first end piece.
In an example shown, surface-to-surface contact between the non-circular projection on the cartridge and the non-circular projection on the access cover is provided, to inhibit air flow therebetween. In general terms, the surface-to-surface contact, provides for a gas flow inhibiting arrangement, which inhibits gas flow between the projection on the cartridge and the projection on the access cover portion, in operation.
In the example arrangement described, the access cover comprises a cover assembly with a regulator valve assembly therein, oriented to regulate gas flow into a central flow aperture of the first end piece. The access cover assembly shown, comprises a cover member and a lower basket member. The regulation valve assembly includes a rolling diaphragm as a valve member positioned between the lower basket member and the cover member.
For an example described, the cover member of the access cover assembly includes a rim member and a cap member, the rim member having a central aperture therethrough and the cap member including a snap-fit projection arrangement projecting through the central aperture of the rim member and into snap-fit engagement with the lower basket member, when the access cover assembly is assembled. When assembled, the rim member, for the example shown, is typically rotatable relative to the gap member and the lower basket member.
In an example arrangement described herein, the access cover assembly includes a third (cap member-to-basket member or basket member-to-cap member) rotational alignment indexing arrangement thereon. This arrangement provides for only a single, selected, rotational alignment between the cap member and the lower basket member, when the access cover assembly is assembled. This cartridge rotational alignment indexing arrangement is shown as comprising for example a projection/receiver arrangement including at least one, and typically more than one, projection in the cap member engageable with a receiver (typically multiple receivers) on the lower basket member only when the cap member and lower basket member are rotationally aligned correctly in a single, selected, rotational orientation, during assembly.
For the example shown, the cap member-to-basket member rotational alignment indexing arrangement includes: snap-fit projections on the cap member engageable with a rim end portion of the basket member having flanges thereon oriented between selected snap-fit projections; and, a pair of projections on the cap member received within a pair of cylindrical receivers on the lower basket member. Alternatives are possible.
It is also characterized herein that a crankcase ventilation filter assembly is provided includes a housing defining an interior having a housing base and a removable access cover, the housing base including a gas flow inlet, a gas flow outlet and a liquid drain outlet; the access cover including a first member of a rotational indexing arrangement therein, which arrangement comprises a cartridge-to-access cover portion (or access cover portion-to-cartridge) rotational alignment indexing arrangement.
The assembly would typically include a serviceable filter cartridge therein, with a media pack and a first end piece. The first end piece would include a second member of the cartridge-to-access cover portion rotational alignment indexing arrangement, requiring the selected portion of the access cover to be in a single selected rotational orientation relative to the cartridge, of the overall assembly configured for use. As an example, a D-shaped projection on the access cover is portion provided in engagement with a D-shaped projection on the cartridge, to provide for a single rotational orientation.
In an example, a D-shaped projection on the access cover portion engages the D-shaped projection on the cartridge in a manner providing for gas flow inhibition therebetween, typically by surface-to-surface contact.
In another aspect of the present disclosure, a crankcase ventilation filter assembly is provided comprising a housing defining an interior and including a housing base and a removable access cover. The housing base includes a gas flow inlet, a gas flow outlet and a liquid flow outlet. The housing base further includes a lower cylindrical portion having a first circular interior cross-section and an upper cylindrical portion of a second circular interior cross-section. The first circular interior cross-section is eccentrically aligned with the second interior cross-section. Typically the lower cylindrical portion includes an upper projection with the first seal surface and the upper cylindrical portion includes a threaded outer surface and an opposite, second, inner seal surface. The access cover is removably threaded onto the upper cylindrical portion with a seal member positioned between a portion of the access cover and the second, opposite, inner seal surface. The housing defines a gas/liquid flow gutter arrangement extending from a location adjacent the inlet at least partially around the housing base, the gas/liquid flow gutter arrangement being positioned between an upper flange of the lower cylindrical portion and the upper cylindrical portion. The gas/liquid flow gutter arrangement includes an upwardly directed ramp section.
In this assembly, a serviceable filter cartridge for use in separating a hydrophobic liquid aerosol phase from a gas stream is perfectly positioned within the housing interior. The cartridge includes a media pack comprising filter media surrounding an open filter interior and including first and second opposite media ends and a first end piece adjacent the first end of the media pack, including a perimeter seal arrangement thereon and a central flow aperture arrangement therethrough. The perimeter housing seal arrangement is sealed to the first seal surface of the housing.
In a typical embodiment, the filter cartridge includes a second end piece positioned spaced from the first end piece with the media pack positioned therebetween. The second end piece includes an outer perimeter section comprising a plurality of drain regions, each drain region being, at least in part, in direct drain overlap with the end of the media and the media pack at a location adjacent the second end piece.
According to a further aspect of the present disclosure, a crankcase ventilation filter assembly is provided comprising a housing defining an interior and including a housing base and a removable access cover. The housing base includes a gas flow inlet, a gas flow outlet and a liquid drain outlet. The housing base includes an upper threaded end. The access cover comprises a cover assembly with a regulator valve assembly therein oriented to regulate gas flow valve into a central flow aperture of a first end piece of an installed cartridge. The access cover assembly includes a cover member and a lower basket member. Regulator valve assembly includes a diaphragm positioned between the cover member and the lower basket, when the cover member is secured to the lower basket.
In an example described, the cover member comprises a rim member and a cap member. The rim member includes a central aperture therethrough and the cap member includes a snap-fit projection arrangement projecting through the central aperture and the rim member and into snap-fit engagement with a lower basket member. In this arrangement, the rim member is typically rotatable relative to the cap member and the lower basket member.
Typically, a serviceable filter cartridge for use in separating a hydrophobic liquid aerosol phase from a gas stream is operably positioned in the housing interior. The cartridge includes a media pack comprising filter media surrounding an open filter interior including first and second opposite media ends and a first end piece adjacent the first end of the media pack including a perimeter housing seal arrangement thereon and a central flow aperture arrangement therethrough. The central flow aperture arrangement is in flow communication with the open filter interior. The perimeter housing seal arrangement is sealed to a portion of the housing base.
Claims
1. A filter cartridge for use in separating a hydrophobic liquid aerosol phase from a gas stream and for use in filtering the gas stream; the filter cartridge comprising:
- (a) a media pack comprising filtration media surrounding an open interior and including first and second, opposite, ends;
- (b) a first end piece adjacent the first end of the media pack; the first end piece having a first, outer, end surface on an opposite side of the first end piece from the media pack; (i) the first end piece including a perimeter housing seal arrangement thereon; (ii) the first end piece including a central flow aperture arrangement projecting therethrough in communication with the open interior of the media pack; and (iii) the first end piece including a non-circular projection positioned around the central flow aperture arrangement and projecting from the first end piece in a direction axially opposite the media pack; the non-circular projection being positioned spaced from an outer perimeter of the first end piece.
2. A filter cartridge according to claim 1 wherein:
- (a) the non-circular projection is non-continuous and includes a liquid drain gap arrangement therethrough.
3. A filter cartridge according to claim 2 wherein:
- (a) the non-circular projection defines an outer perimeter with a first straight side portion and an opposite curved side portion.
4. A filter cartridge according to claim 3 wherein:
- (a) the drain gap arrangement comprises a gap in the first straight side portion.
5-6. (canceled)
7. A filter cartridge according to claim 1 including:
- (a) a handle member positioned on the first end piece and projecting in a direction away from the media pack; (i) the handle member being non-collapsible and including a handle bridge section forming a handle opening thereunder between the handle bridge section and an adjacent portion of the first end piece; the handle opening being sized to permit at least a portion of a person's hand to project therethrough.
8. A filter cartridge according to claim 7 wherein:
- (a) the handle member comprises a perimeter handle member positioned adjacent the outer perimeter of the first end piece.
9. A filter cartridge according to claim 8 wherein:
- (a) the perimeter handle member is radially positioned with the handle opening aligned with, and directed toward, a first straight side of the non-circular projection.
10. A filter cartridge according to claim 1 including:
- (a) the first end piece includes a peripheral rim projection extending in a direction away from the media pack; (i) the peripheral rim projection surrounding a recessed surface portion of the first end piece; the recessed surface portion extending between the peripheral rim projection and the non-circular projection.
11. (canceled)
12. A filter cartridge according to claim 1 wherein:
- (a) the first end piece includes a first member of a cartridge-to-housing rotational alignment indexing arrangement comprising a first radial projection spaced from a first locator shoulder to define a first locator receiver gap therebetween.
13. A filter cartridge according to claim 12 wherein:
- (a) the first member of a cartridge-to-housing rotational alignment indexing arrangement includes a second radial projection spaced from a second locator shoulder to define a second locator receiving gap therebetween; (i) the first and second locator gaps being radially spaced, on center, a smallest radial amount of less than 180°.
14. A filter cartridge according to claim 1 including:
- (a) a second end piece positioned spaced from the first end piece with the media pack positioned therebetween.
15. A filter cartridge according to claim 14 wherein:
- (a) the second end piece and the first end piece are positioned at opposite ends of a central, tubular, media support extending through the open interior of the media pack.
16. (canceled)
17. A filter cartridge according to claim 15 wherein:
- (a) the second end piece includes: (i) a closed central portion overlapping, and closing, an end of the open interior of the media pack; and, (ii) an outer perimeter section comprising a plurality of spaced projections and a plurality of drain regions between the spaced projections; each drain region being at least in part, in direct drain overlap with an end of media in the media pack at a location adjacent the second end piece.
18. A filter cartridge according to claim 17 wherein:
- (a) the closed central portion of the second end piece is positioned projecting into the end of the open interior of the media pack; and,
- (b) the second end piece includes a closed transition portion between the closed central portion and the outer perimeter section;
19. A crankcase ventilation filter assembly comprising:
- (a) a housing defining an interior and including a housing base and a removable access cover; (i) the housing defining a gas flow inlet, a gas flow outlet and a liquid drain outlet; and, (ii) the housing base including a first member of a cartridge-to-housing base rotational alignment indexing arrangement thereon; and,
- (b) a serviceable filter cartridge for use in separating a hydrophobic liquid aerosol phase from a gas stream; the filter cartridge being operably positioned in the housing interior and including: (i) a media pack comprising filter media surrounding an open filter interior and including first and second, opposite, media ends; (ii) a housing seal arrangement; (A) the housing seal arrangement being sealed to a portion of the housing base; (iii) a first end piece adjacent the first end of the media pack including a central flow aperture therethrough in flow communication with the open filter interior; and, (iv) the cartridge including a second member of the cartridge-to-housing base rotational alignment indexing arrangement thereon oriented engaging the first member of the cartridge-to-housing rotational indexing arrangement in the housing base to require the cartridge to be in a selected, single, rotational orientation in the housing base when the cartridge is operably positioned in the housing base.
20. (canceled)
21. A crankcase ventilation filter assembly according to claim 19 wherein:
- (a) the first member of the cartridge-to-housing base rotational alignment indexing arrangement includes a first projecting tab on the housing base; and,
- (b) the second member of the cartridge-to-housing base rotational alignment indexing arrangement includes a first receiver space defined between a first radial projection and a first shoulder oriented on the first end piece of the filter cartridge.
22. (canceled)
23. A crankcase ventilation filter assembly according to claim 19 wherein:
- (a) the access cover includes a first member of a cartridge-to-access cover portion rotational alignment indexing arrangement thereon; and,
- (b) the filter cartridge includes a second member of a cartridge-to-access cover portion rotational alignment indexing arrangement thereon; (i) the first and second members of the cartridge-to-access cover portion rotational indexing alignment arrangement being engageable to provide a selected, single, rotational alignment between the filter cartridge and a portion of the access cover.
24-28. (canceled)
29. A crankcase ventilation filter assembly according to claim 19 wherein:
- (a) the access cover assembly comprises a cover member and a lower basket member; and
- (b) the regulator valve assembly includes a diaphragm; (i) the cover member of the access cover assembly is secured to the lower basket member with a portion of the diaphragm secured therebetween.
30-32. (canceled)
33. A crankcase ventilation filter assembly comprising:
- (a) a housing defining an interior and including a housing base and a removable access cover; (i) the housing including a gas flow inlet, a gas flow outlet and a liquid drain outlet; (ii) the access cover including a first member of a cartridge-to-access cover portion rotational indexing arrangement thereon;
- (b) a serviceable filter cartridge for use in separating a hydrophobic liquid aerosol phase from a gas stream; the filter cartridge being operably positioned within the housing interior and including: (i) a media pack comprising filter media surrounding an open filter interior and including first and second, opposite, media ends; and, (ii) a first end piece adjacent the first end of the media pack including a perimeter seal arrangement thereon and a central flow aperture arrangement therethrough; (A) the perimeter housing seal arrangement being sealed to a portion of the housing base; and (B) the first end piece including a second member of the cartridge-to-access cover portion rotational alignment indexing arrangement thereon oriented engaging the first member of the cartridge-to-access cover portion rotational indexing arrangement to position the filter cartridge and a selected portion of the access cover in a single, selected, rotational alignment with one another.
34. A crankcase ventilation filter assembly according to claim 33 wherein:
- (a) the first member of the cartridge-to-access cover portion rotational alignment indexing arrangement comprises a D-shaped projection on a portion of the access cover; and,
- (b) the second member of the cartridge-to-access cover rotational alignment indexing arrangement comprises a D-shaped projection positioned on the first end piece of the filter cartridge, around the central flow aperture.
35-37. (canceled)
38. A crankcase ventilation filter assembly comprising:
- (a) a housing defining an interior and including a housing base and a removable access cover; (i) the housing base including a gas flow inlet, a gas flow outlet and a liquid flow outlet; the housing base further including: (A) a lower cylindrical portion having a first circular interior cross-section; and (B) an upper cylindrical portion having a second circular interior cross-section; (C) the first circular interior cross-section being eccentrically aligned with the second interior cross-section; (D) the lower cylindrical portion including an upper projection with a first inner seal surface; (E) the upper cylindrical portion including a threaded outer surface and an opposite inner seal surface; (F) the access cover being removably threaded onto the upper cylindrical portion with a seal member positioned between a portion of the access cover and the second inner seal surface; and, (G) the housing defining an gas/liquid flow gutter arrangement extending from a location adjacent the inlet at least partially around the housing base; the gas/liquid flow gutter arrangement being positioned between an upper flange of the lower cylindrical portion and the upper cylindrical portion; the air/liquid flow gutter arrangement including an upwardly directed ramp section; and,
- (b) a serviceable filter cartridge for use in separating a hydrophobic liquid aerosol phase from a gas stream; the filter cartridge being operably positioned within the housing and including: (i) a media pack comprising filter media surrounding an open filter interior and including first and second, opposite, media ends; and, (ii) a first end piece adjacent the first end of the media pack including a perimeter seal arrangement thereon and a central flow aperture arrangement therethrough; (A) the perimeter housing seal arrangement being sealed to the first inner seal surface.
39. (canceled)
40. A crankcase ventilation filter assembly comprising:
- (a) a housing defining an interior and including a housing base and a removable access cover; (i) the housing base including a gas flow inlet, a gas flow outlet and a liquid drain outlet; (ii) the housing base including an upper, threaded, end; (iii) the access cover comprising a cover assembly with a regulator valve assembly therein oriented to regulate gas flow into a central flow aperture of a first end piece of an installed cartridge; (A) the access cover assembly including a cover member and a lower basket member; (B) the regulator valve assembly including a diaphragm; the cover member being secured to the lower basket member with a portion of the diaphragm secured therebetween; and, (C) the cover member comprising a rim member and a cap member; (1) the rim member including a central aperture therethrough; and, (2) the cap member including a snap-fit projection arrangement projecting through the central aperture in the rim member and into snap-fit engagement with the lower basket member; the rim member being rotatable relative to the cap member and the lower basket member; and,
- (b) a serviceable filter cartridge for use in separating a hydrophobic liquid aerosol phase from a gas stream; the filter cartridge being operably positioned in the housing interior and including: (i) a media pack comprising filter media surrounding an open filter interior and including first and second, opposite, media ends; and, (ii) a first end piece adjacent the first end of the media pack including a perimeter housing seal arrangement thereon and a central flow aperture therethrough in flow communication with the open filter interior; the perimeter housing seal arrangement being sealed to a portion of the housing base.
41. A filter cartridge for use in separating a hydrophobic aerosol phase from a gas stream and for use in filtering the gas stream; the filter cartridge comprising:
- (a) a media pack comprising filtration media surrounding an open interior and including first and second, opposite, ends;
- (b) a cartridge support piece comprising first and second end pieces and an interior support; (i) the media pack being positioned on the cartridge support piece between the first and second end pieces with the interior support extending through the media pack open interior; (ii) the first and second end pieces and interior support being formed integral with one another; and, (iii) the first end piece including a central aperture therethrough;
- (c) the cartridge support piece including a handle member positioned on the first end piece and projecting in a direction away from the media pack; (i) the handle member being non-collapsible and including a handle bridge section forming a handle opening thereunder between the handle bridge section and an adjacent portion of the first end piece; and,
- (d) a radially outwardly directed seal member.
42. A filter cartridge according to claim 41 wherein:
- (a) the handle bridge section is arcuate in extension partially around the central aperture.
43. A filter cartridge according to claim 41 wherein:
- (a) the handle bridge section extends over an arcuate extension of at least 30°.
44-47. (canceled)
Type: Application
Filed: Mar 19, 2008
Publication Date: Oct 27, 2011
Patent Grant number: 8758467
Applicant: Donaldson Company, Inc. (Minneapolis, MN)
Inventors: Thomas John Lundgren (Bloomington, MN), Bradley Allen Hemish (Coon Rapids, MN), Daniel Eric Adamek (Bloomington, MN), Wade Stephen Mosset (Savage, MN)
Application Number: 12/450,244
International Classification: B01D 46/24 (20060101); B01D 46/26 (20060101); B01D 46/42 (20060101);